Junk crushing device, assembly, and method thereof

Abstract

A junk crusher device for crushing junk in a fluid stream includes a circular plate and a shaft. The circular plate includes fluid stream discharge holes and a bearing. The shaft is disposed within the bearing and includes detachably connected tear blades that are configured to rotate with the shaft. The junk crusher device further includes an impeller, hydraulically driven by the fluid stream, configured to rotate the shaft, an internal housing including fixed blades, and a body configured to receive the internal housing such that the internal housing is secured to an interior of the body. The rotating tear blades and fixed blades are configured to crush junk in the fluid stream. The fluid stream discharge holes disposed in the circular plate are configured to filter crushed junk.

What is claimed is: 
     
       1. A junk crusher device for crushing junk in a fluid stream comprising:
 a circular plate comprising fluid stream discharge holes and a bearing; 
 a shaft disposed within the bearing, the shaft comprising detachably connected tear blades that are configured to rotate with the shaft; 
 an impeller, hydraulically driven by the fluid stream, configured to rotate the shaft; 
 an internal housing comprising fixed blades, 
 a body configured to receive the internal housing such that the internal housing is secured to an interior of the body; 
 wherein the internal housing is formed of a plurality of sections, each section of the plurality of sections being configured to be installed within the body one after another in sequential fashion 
 the tear blades and the fixed blades are configured to crush junk in the fluid stream; and 
 wherein the fluid stream discharge holes disposed in the circular plate are configured to filter crushed junk. 
 
     
     
       2. The junk crusher device according to  claim 1 , wherein the impeller is disposed at an end of the shaft outside of the internal housing. 
     
     
       3. The junk crusher device according to  claim 1 , wherein the tear blades comprise raised burrs. 
     
     
       4. The junk crusher device according to  claim 1 , wherein a first section of the internal housing installed within the body comprises the circular plate. 
     
     
       5. The junk crusher device according to  claim 1 , wherein the fixed blades are fixed to at least two of the plurality of sections of the internal housing such that each blade of the fixed blades is disposed in a separate section of the internal housing. 
     
     
       6. The junk crusher device according to  claim 1 , wherein each section of the plurality of sections of the internal housing is disposed concentrically on a common axis. 
     
     
       7. The junk crusher device according to  claim 5 , wherein the fixed blades and the tear blades are vertically arranged in an alternating fashion. 
     
     
       8. The junk crusher device according to  claim 7 , wherein a distance between the fixed blades and the tear blades is smaller than a diameter of the fluid stream discharge holes of the circular plate. 
     
     
       9. A method for crushing junk in a fluid stream, comprising:
 assembling an internal housing within a body, 
 wherein the assembling comprises connecting a plurality of sections of the internal housing in sequential fashion; 
 supporting, by a bearing disposed in a circular plate, a shaft comprising externally integrated tear blades; 
 rotating, by a hydraulically driven impeller, the shaft and the tear blades together; 
 crushing, by the tear blades and by fixed blades formed to the internal housing, junk in the fluid stream; and 
 filtering, by fluid stream discharge holes disposed in the circular plate, crushed junk. 
 
     
     
       10. The method according to  claim 9 , wherein the assembling further comprises installing a first section of the plurality of sections, the first section comprising the circular plate. 
     
     
       11. The method according to  claim 9 , further comprising attaching the impeller to the shaft subsequent to the connecting of the plurality of sections of the internal housing such that the impeller is disposed outside of the internal housing. 
     
     
       12. The method according to  claim 9 , wherein each section of the plurality of sections of the internal housing is disposed concentrically on a common axis. 
     
     
       13. The method according to  claim 9 , further comprising fixing the fixed blades to at least two of the plurality of sections of the internal housing such that each blade of the fixed blades is disposed in a separate section of the internal housing. 
     
     
       14. The method according to  claim 12 , further comprising arranging the plurality of sections such that the fixed blades and the tear blades alternate within the body. 
     
     
       15. The method according to  claim 14 , wherein a distance between the fixed blades and the tear blades is smaller than a diameter of the fluid stream discharge holes of the circular plate. 
     
     
       16. A junk crusher assembly for crushing junk in a fluid stream, the junk crusher assembly comprising:
 a junk crusher device comprising:
 a circular plate comprising fluid stream discharge holes and a bearing; 
 a shaft disposed within the bearing, the shaft comprising detachably connected tear blades that are configured to rotate with the shaft; 
 an impeller, hydraulically driven by the fluid stream, configured to rotate the shaft; 
 an internal housing comprising fixed blades; and 
 a body configured to receive the internal housing such that the internal housing is secured to an interior of the body; 
 
 a baffle plate configured to block junk that would not fit in the junk crusher device; 
 a float valve configured to control the fluid stream such that the fluid stream flows in a single direction, 
 wherein the float valve is disposed at a downhole end of the junk crusher assembly; and 
 a casing configured to house the junk crusher device, the baffle plate, and the float valve. 
 
     
     
       17. The junk crusher assembly of  claim 16 , wherein the junk crusher device is disposed between the baffle plate and the float valve. 
     
     
       18. The junk crusher assembly of  claim 17 , wherein the float valve is a spring assisted non-return valve.